General body repairs, exterior

Chapter overview

• Technical data
  1
• 1 Safety information
  1
• 1.1 Safety measures when working on vehicles with start/stop system
  1
• 2 Repair instructions
  2
• 2.1 Routing and attachment of lines
  2
• 2.2 Contact corrosion
  2
• 2.3 Bonding surfaces for self-adhesive components
  2
• 2.4 Secured threaded connections
  2
• Body - front
  3
• 1 Lock carrier
  3
• 1.1 Assembly overview – lock carrier
  3
• 1.2 Removing and installing lock carrier
  4
• 1.3 Moving to and back from service position
  7
• 1.4 Repairing lock carrier
  11
• 2 Wings
  14
• 2.1 Assembly overview – wing
  14
• 2.2 Removing and installing wing
  14
• 3 Bulkhead
  20
• 3.1 Assembly overview – bulkhead
  20
• 3.2 Assembly overview – plenum chamber cover
  21
• 3.3 Removing and installing bulkhead
  22
• 3.4 Removing and installing plenum chamber cover
  25
• Bonnet, rear lid
  31
• 1 Bonnet
  31
• 1.1 Assembly overview – bonnet
  31
• 1.2 Assembly overview – Bowden cable
  32
• 1.3 Assembly overview - gas strut
  33
• 1.4 Removing and installing bonnet
  34
• 1.5 Resetting hinge
  36
• 1.6 Adjusting bonnet
  38
• 1.7 Removing and installing rear lid lock
  44
• 1.8 Removing and installing bonnet lock operating lever
  49
• 1.9 Removing and installing striker pin
  51
• 1.10 Removing and installing hinges
  53
• 1.11 Removing and installing insulation
  55
• 1.12 Removing and installing gas strut
  57
• 1.13 Releasing gas from gas strut
  59
• 1.14 Removing and installing Bowden cable
  59
• 2 Rear lid
  63
• 2.1 Assembly overview – rear lid
  63
• 2.2 Removing and installing rear lid
  65
• 2.3 Adjusting rear lid
  69
• 2.4 Removing and installing rear lid lock
  75
• 2.5 Removing and installing operating mechanism
  87
• 2.6 Removing and installing hinges
  88
• 2.7 Removing and installing striker pin
  91
• 2.8 Removing and installing rear lid seal
  92
• 2.9 Removing and installing gas strut
  94
• 2.10 Releasing gas from gas strut
  96
• 2.11 Removing and installing rear lid drive unit VX69
  96
• 3 Tank flap unit
  101
• 3.1 Assembly overview – tank flap unit
  101
• 3.2 Removing and installing tank flap unit
  101
• 3.3 Removing and installing fuel tank flap
  104
• Front doors, door components, central locking
  107
• 1 Door
  107
• 1.1 Assembly overview – door
  107
• 1.2 Removing and installing inner door seal
  110
• 1.3 Removing and installing outer door seal
  112
• 1.4 Removing and installing door
  114
• 1.5 Adjusting door
  117
• 1.6 Adjusting striker pin
  120
• 1.7 Removing and installing door arrester
  122
• 2 Door components
  125
• 2.1 Assembly overview – door components
  125
• 2.2 Assembly overview – window regulator
  127
• 2.3 Assembly overview – door handle and door lock
  128
• 2.4 Removing and installing window regulator motor
  129
• 2.5 Removing and installing window regulator
  132
• 2.6 Removing and installing inner door cover
  135
• 2.7 Removing and installing striker pin
  138
• 2.8 Removing and installing cap on door handle
  139
• 2.9 Removing and installing lock cylinder
  145
• 2.10 Removing and installing door handle
  149
• 2.11 Removing and installing mounting bracket
  151
• 2.12 Removing and installing door lock
  153
• 2.13 Removing and installing window channel
  158
• 2.14 Removing and installing window slot outer seal
  161
• 2.15 Removing and installing window slot inner seal
  163
• 3 Central locking
  164
• 3.1 Overview of fitting locations – central locking system
  164
• 3.2 Removing and installing tank filler flap locking motor V155
  166
• 3.3 Removing and installing ignition key battery
  167
• 3.4 Removing and installing cap on ignition key
  169
• Rear doors, door components
  171
• 1 Door
  171
• 1.1 Assembly overview – door
  171
• 1.2 Removing and installing door
  174
• 1.3 Adjusting door
  176
• 1.4 Adjusting striker pin
  179
• 1.5 Removing and installing door arrester
  181
• 1.6 Removing and installing inner door seal
  183
• 1.7 Removing and installing outer door seal
  186
• 2 Door components
  188
• 2.1 Assembly overview – door components
  188
• 2.2 Assembly overview – window regulator
  190
• 2.3 Assembly overview – door handle and door lock
  190
• 2.4 Removing and installing window regulator motor
  191
• 2.5 Removing and installing window regulator
  194
• 2.6 Removing and installing inner door cover
  197
• 2.7 Removing and installing striker pin
  199
• 2.8 Removing and installing cap on door handle
  201
• 2.9 Removing and installing door handle
  205
• 2.10 Removing and installing mounting bracket
  207
• 2.11 Removing and installing door lock
  210
• 2.12 Removing and installing door padding
  214
• 2.13 Removing and installing window channel
  216
• 2.14 Removing and installing window slot outer seal
  219
• 2.15 Removing and installing window slot inner seal
  220
• Sunroof
  222
• 1 Sliding sunroof
  222
• 1.1 Assembly overview – sliding sunroof
  222
• 1.2 Assembly overview – sunroof roller blind
  224
• 1.3 Assembly overview – wind deflector
  224
• 1.4 Removing and installing sunroof panel
  225
• 1.5 Removing and installing rear sunroof panel
  229
• 1.6 Adjusting sunroof panel
  233
• 1.7 Removing and installing sliding sunroof frame
  237
• 1.8 Removing and installing rear part
  240
• 1.9 Removing and installing tilt mechanism for sliding sunroof
  245
• 1.10 Removing and installing sunroof roller blind cables
  247
• 1.11 Removing and installing wind deflector
  250
• 1.12 Removing and installing sunroof motor V1
  253
• 1.13 Removing and installing sunroof roller blind motor V260
  255
• 1.14 Removing and installing roller blind adjustment control unit J394
  257
• 1.15 Removing and installing J245sliding sunroof adjustment control unit
  258
• 1.16 Manual operation
  260
• 1.17 Removing and installing sliding sunroof seals
  262
• 1.18 Removing and installing sunroof roller blind
  266
• 1.19 Programming sliding sunroof adjustment control unit J245
  271
• 1.20 Adapting sunroof roller blind control unit J394
  271
• 2 Water drain hoses
  272
• 2.1 Assembly overview - water drain hoses
  272
• 2.2 Cleaning water drain hoses
  272
• 2.3 Removing and installing water drain hoses
  274
• Bumpers
  277
• 1 Bumper, front
  277
• 1.1 Assembly overview – bumper cover
  277
• 1.2 Assembly overview - add-on parts
  278
• 1.3 Assembly overview – bumper carrier
  281
• 1.4 Removing and installing bumper cover
  282
• 1.5 Repairing bumper cover
  286
• 2 Bumper, rear
  296
• 2.1 Assembly overview – bumper cover
  296
• 2.2 Assembly overview - guides for bumper cover
  297
• 2.3 Assembly overview - add-on parts
  297
• 2.4 Assembly overview – bumper carrier
  299
• 2.5 Removing and installing bumper cover
  300
• 2.6 Removing and installing bumper carrier
  303
• 2.7 Repairing bumper cover
  305
• Glazing
  315
• 1 Repair instructions
  315
• 1.1 Minimum drying times for bonded windows
  315
• 1.2 Window repair
  315
• 1.3 Installation instructions for bonded windows
  316
• 1.4 Preparing old undamaged windows for installing
  317
• 1.5 Preparing new windows for installing
  318
• 1.6 Preparing body flange for installing
  319
• 1.7 Cleaning off excess adhesive
  321
• 2 Windscreen
  322
• 2.1 Assembly overview – windscreen
  322
• 2.2 Removing and installing windscreen
  323
• 3 Rear windscreen
  331
• 3.1 Assembly overview – rear window
  331
• 3.2 Removing and installing rear window
  332
• 4 Side windows
  336
• 4.1 Assembly overview - front side window
  336
• 4.2 Assembly overview - rear side windows
  336
• 4.3 Removing and installing front side window
  337
• 4.4 Removing and installing rear side window
  341
• 5 Door windows
  346
• 5.1 Assembly overview - front door window
  346
• 5.2 Assembly overview - rear door window
  346
• 5.3 Removing and installing front door window
  347
• 5.4 Removing and installing rear door window
  351
• 5.5 Removing and installing fixed rear door window
  355
• Exterior equipment
  357
• 1 Radiator grille and front trim
  357
• 1.1 Assembly overview – radiator grille
  357
• 1.2 Removing and installing radiator grille
  358
• 2 Spoiler
  361
• 2.1 Assembly overview - side spoiler
  361
• 2.2 Removing and installing side spoiler
  361
• 3 Mouldings, trims, extensions
  364
• 3.1 Assembly overview – side member trim
  364
• 3.2 Assembly overview – water deflector
  365
• 3.3 Assembly overview - heat shield
  365
• 3.4 Removing and installing water deflector
  366
• 3.5 Removing and installing B-pillar trim
  368
• 3.6 Removing and installing trim strip
  370
• 3.7 Removing and installing step moulding
  372
• 3.8 Removing and installing side member trim
  374
• 3.9 Removing and installing underbody heat shield
  379
• 4 Noise insulation
  383
• 4.1 Assembly overview - noise insulation
  383
• 5 Underbody cladding
  386
• 5.1 Overview of fitting locations - underbody cladding
  386
• 5.2 Removing and installing underbody cladding
  387
• 5.3 Removing and installing tunnel cross-piece
  392
• 6 Roof moulding and roof railing
  395
• 6.1 Assembly overview - roof railing
  395
• 6.2 Removing and installing roof railing
  395
• 7 Exterior mirror
  398
• 7.1 Assembly overview – exterior mirror
  398
• 7.2 Removing and installing exterior mirror
  400
• 7.3 Removing and installing mirror glass
  402
• 7.4 Removing and installing mirror adjustment unit
  404
• 7.5 Removing and installing mirror cover
  406
• 7.6 Removing and installing mirror frame
  407
• 8 Wheel housing liner
  409
• 8.1 Assembly overview – front wheel housing liner
  409
• 8.2 Assembly overview – rear wheel housing liner
  410
• 8.3 Removing and installing front wheel housing liner
  411
• 8.4 Removing and installing rear wheel housing liner
  413
• 9 Lettering and emblems
  415
• 9.1 Dimensions - lettering and emblems on rear
  415
• 9.2 Dimensions – lettering and emblems on sides
  419
• 9.3 Removing and installing badges at front
  422
• 9.4 Renewing lettering and badges at rear
  425
• 9.5 Renewing lettering and badges on sides
  427
• 10 Special add-on parts
  429
• 10.1 Assembly overview – special add-on parts
  429
• 11 Towing bracket
  430
• 11.1 Assembly overview – towing bracket
  430
• 11.2 Removing and installing towing bracket
  431
• 11.3 Removing and installing trigger unit
  433